Fatigue Analysis and Redesign of Carrier Kingpin

Photo of Daniel Kinneman, Daniel Meserve, Eduardo Tapia, Mark Wachowicz Students: Daniel Kinneman, Daniel Meserve, Eduardo Tapia, Mark Wachowicz

Sponsor: General Motors

Date: Spring 2012

Requirements:
The Carrier Kingpin must fit in the pre-cast trolley, limiting the allowable geometric changes for increasing pin strength and life. However, due to the presence of a spacer between the trolley and bottom of the kingpin head, the possibility of implementing a fillet in the area where the cylindrical shaft of the pin meets the pin-head is a viable avenue for redesign.

Problem:
The scope of this project includes performing stress and fatigue analysis on a Carrier Kingpin in an existing trolley assembly to predict the cycles to failure, estimate the length of time between pin replacements, and suggest design changes to improve these parameters.

Solution:
Using accelerometer data provided by GM, the senior design team determined the reaction forces and moments applied to the pin. These forces and moments were used as boundary conditions in a SolidWorks/COSMOS® simulation. The simulation estimated a maximum von Mises stress of 815 MPa in the area of typical breakage. Fatigue analysis was performed with Miner's Rule to determine a typical kingpin life of roughly 47 months. A redesigned, filleted kingpin was then analyzed. The estimated life of the redesigned kingpin is 14 times greater than that for the original kingpin.

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